LED luminaire with mounting structure for LED circuit board

Abstract

An LED luminaire includes a reflector, a channel, and a printed circuit board (PCB) onto which LEDs are mounted. Each of the reflector, the channel, and the PCB includes a feature(s) that permit their attachment to each other without the need for separate fasteners and tools. Embodiments of the LED luminaire may also include an optic and a pair of end caps, also designed for assembly into the LED luminaire without the use of or need for separate fasteners and tools.

That which is claimed is: 
     
       1. A luminaire comprising:
 a reflector having two opposing ends and a channel-receiving portion, the channel-receiving portion extending between the two opposing ends and comprising reflector clips in the channel-receiving portion; 
 a channel comprising opposing side edges each having a length, the channel further comprising clip apertures and side channel tabs, wherein the side channel tabs extend a distance along the length of the opposing side edges of the channel and extend upwardly from the channel, the channel mounted on the reflector such that the reflector clips are engaged with the channel through the clip apertures; 
 a first printed circuit board (PCB) mounted on the channel by positioning opposing side edges of the first PCB under the side channel tabs, the opposing side edges of the first PCB each having a length and notches extending a distance along the length of the opposing side edges of the first PCB, wherein the distance of one of the notches on the first PCB is at least as great as the distance of one of the side channel tabs on the channel such that the notches on the first PCB can receive the side channel tabs; 
 a second PCB, wherein the channel further comprises center tabs and end tabs, the center tabs between the end tabs, wherein the first PCB is mounted on the channel between a one of the end tabs and a one of the center tabs, wherein the second PCB is mounted on the channel between a second of the end tabs and a second of the center tabs, and wherein the center tabs define a wire pathway between the center tabs, and wherein the wire pathway is dimensioned to accommodate at least one wire of the luminaire; and 
 a plurality of light emitting diodes (LEDs) provided on the first PCB. 
 
     
     
       2. The luminaire of  claim 1 , further comprising an optic having opposing ends and opposing side edges that engage the opposing side edges of the channel. 
     
     
       3. The luminaire of  claim 2 , further comprising a pair of end caps, each one of the pair of end caps mounted to an opposing end of the reflector, wherein each end cap comprises an end cap groove and wherein a one opposing end of the optic engages the end cap groove in one of the pair of end caps. 
     
     
       4. The luminaire of  claim 3 , wherein the reflector further comprises end cap tabs extending from the opposing ends of the reflector, wherein each one of the pair of end caps comprises end cap slots, and wherein the pair of end caps are mounted at the opposing ends of the reflector such that the end cap tabs extend through the end cap slots. 
     
     
       5. The luminaire of  claim 2 , wherein the opposing side edges of the channel are angled. 
     
     
       6. The luminaire of  claim 1 , wherein the clip apertures and side channel tabs of the channel are formed integrally with the channel. 
     
     
       7. The luminaire of  claim 1 , wherein the end tabs are at opposing ends of the channel. 
     
     
       8. The luminaire of  claim 1 , further in comprising at least one of a radio frequency (RF) antenna or an infra-red (IR) sensor mounted on the channel adjacent to the first PCB. 
     
     
       9. A luminaire comprising:
 a reflector having two opposing ends and a channel-receiving portion, the channel-receiving portion extending between the two opposing ends and comprising reflector arms in the channel-receiving portion; 
 a channel comprising opposing side edges each having a length, the channel further comprising channel apertures provided along the length of each of the opposing side edges of the channel and end tabs at opposing end edges of the channel, the channel mounted on the reflector such that the reflector arms are engaged with the channel through the channel apertures; 
 a printed circuit board (PCB) having PCB apertures, the PCB mounted on the channel such that the PCB is between the end tabs of the channel and the reflector arms extend through the PCB apertures; and 
 a plurality of light emitting diodes (LEDs) provided on the PCB, 
 wherein the PCB is a first PCB, wherein the luminaire further comprises a second PCB, wherein the channel further comprises center tabs between the end tabs, wherein the first PCB is mounted on the channel between a one of the end tabs and a one of the center tabs, wherein the second PCB is mounted on the channel between a second of the end tabs and a second of the center tabs, and wherein the center tabs define a wire pathway between the center tabs, and wherein the wire pathway is dimensioned to accommodate at least one wire of the luminaire. 
 
     
     
       10. The luminaire of  claim 9 , wherein the reflector further comprises end cap tabs extending from opposing ends of the reflector, and wherein the luminaire further comprises:
 a pair of end caps, each one of the pair of end caps having end cap slots, the pair of end caps mounted at the opposing ends of the reflector such that the end cap tabs extend through the end cap slots. 
 
     
     
       11. The luminaire of  claim 10 , wherein each one of the pair of end caps comprises an end cap groove, and wherein the luminaire further comprises an optic having opposing ends, wherein each end of the optic engages the end cap groove of one of the pair of end caps. 
     
     
       12. The luminaire of  claim 9 , further comprising at least one of a radio frequency (RF) antenna or an infra-red (IR) sensor mounted on the channel adjacent to the first PCB. 
     
     
       13. The luminaire of  claim 9 , further comprising an optic having opposing ends and opposing side edges that engage the opposing side edges of the channel. 
     
     
       14. The luminaire of  claim 13 , further comprising a pair of end caps, each one of the pair of end caps mounted to an opposing end of the reflector, wherein each end cap comprises an end cap groove and wherein a one opposing end of the optic engages the end cap groove in one of the pair of end caps. 
     
     
       15. The luminaire of  claim 14 , wherein the reflector further comprises end cap tabs extending from the opposing ends of the reflector, wherein each one of the pair of end caps comprises end cap slots, and wherein the pair of end caps are mounted at the opposing ends of the reflector such that the end cap tabs extend through the end cap slots.